Method and apparatus for assembling a complex product in a parallel process system

ABSTRACT

A method and apparatus for assembling a complex product in a parallel process system wherein a collection of components are provided for assembling the complex product. The present invention involves transferring the collection of the components to one of a plurality of similar computerized assembly cells through the use of a transport system. The collection of components is automatically assembled into the complex product through the use of the computerized assembly cells. The complex product is then transferred from one of the assembly cells to a computerized test cell, where the complex product is tested to ensure for the proper dimensioning and functioning of the complex product. The complex product is then transferred from the test cell via the transport system to either a part reject area or conveyor, if the complex product is defective, or to an automatic dunnage load or part return system, if the complex product is not defective.

CROSS-REFERENCE TO RELATED APPLICATIONS

The subject application claims the priority of U.S. Provisional PatentApplication Ser. No. 61/007,307, filed on Dec. 12, 2007.

FIELD OF THE INVENTION

The present invention relates to methods and apparatuses for assemblingcomplex products and, in particular, a method and apparatus forassembling manufacturing products that utilize flexible and programmableassembly and test cells to enhance the quality and efficiency ofassembling a complex product in a parallel process system.

BACKGROUND OF THE INVENTION

In today's manufacturing industry, the customary manner of assemblingproducts is with an assembly line in a serial process system. A serialprocess system is defined as having the complex product travel throughsuccessive, single operations or stations in order to complete theassembly of the complex product. Serial process systems are even morecommon when such products are complex in nature, thereby requiring theassembly of a variety of different subcomponents and various individualcomponents in various locations on the product.

Typically, the serial process of an assembly line begins with thedelivery of a complex product to the assembly line, wherein the complexproduct is then loaded into an assembly line transport system, eitherautomatically or manually. The transport system carries the complexproduct to a variety of workstations along the assembly line, whereinthe various components and subcomponents are assembled into the complexproduct. For example, in a serial processed engine cylinder headassembly line, spark plugs may be installed into the cylinder head atthe first workstation, and after the spark plugs are installed, thetransport system may carry the cylinder head to a second workstation,wherein the cylinder head may be rotated so that additional componentrymay be assembled on the underside or opposite side of the cylinder head.Cylinder head valves may be installed into the cylinder head at asubsequent workstation, and upon traveling to the next workstation, thecylinder head may be rotated back to its original position. Thefollowing workstation may then be responsible for installing valvesprings into the cylinder head. The transport system continues to carrythe cylinder head from workstation to workstation until the cylinderhead is completely assembled. The number of workstations on the assemblyline may vary depending on the type of cylinder head or componentry.Typically, the number of workstations range in the neighborhood of sixto eight with the transport system passing through or adjacent to eachof the workstations.

The timing of the workstations and the transport system is critical forsuch assembly lines. In the above-noted example, the complex productmoves from one workstation to the next, wherein the transport system maystop to allow for an operation to be performed at each of theworkstations. A certain amount of time may even be designated forcompleting a specific task at a specific workstation.

Although assembly lines have been utilized throughout the history of themanufacturing industry, such assembly lines are plagued withinefficiencies. For instance, assembly lines within the automotiveindustry are typically dedicated to a particular component of anautomobile and for a specific model of an automobile. Thus, suchassembly lines cannot be utilized to manufacture any component of anautomobile, but rather, they can be only utilized to build certainspecific components. Therefore, if the particular component is no longerneeded, for instance, if the particular model of automobile in which thecomponent is utilized is no longer being manufactured, then theparticular assembly line cannot be utilized without major retooling.Therefore, the assembly line must be retooled or disassembled, and a newassembly line must be installed. This is, of course, a very timely andcostly task and one that is undesirable in an industrial environment.

As previously mentioned, such assembly lines are typically timed toprovide each laborer at a particular workstation a specific amount oftime under which to complete the operation at that particularworkstation. If a problem occurs at that particular workstation suchthat the task can no longer be performed, for instance, a tool breaks,the transport system shuts down, certain components are defective, etc.,then the entire assembly line may have to be shut down until the problemis corrected. When this occurs, manufacturing of the particular productis halted, thereby causing a shortage of the product being manufacturedor assembled on that particular assembly line. Such a shortage ofproducts could create shortages in other assembly lines therebyrequiring other assembly lines to shut down. Thus, manufacturingfacilities often produce a surplus of components so that a sufficientsupply of components is provided should the assembly line break down orstop. Such uncertainty in the operation of the assembly line may lead toa shortage or a surplus of components. A shortage of components may leadto other assembly lines being short of parts, and a surplus ofcomponents may mean that unnecessary parts have been produced, therebywasting time and money. Either situation creates an inefficiency that isundesirable in an industrial environment.

Lastly, assembly lines often span across a rather large area of themanufacturing facility in order to provide a sufficient amount of spacefor the transport system, the work stations, and the laborers. The floorspace in a manufacturing facility can be rather expensive, andtherefore, it is always desirable to reduce the amount of floor space toproduce a particular product.

It would be desirable to produce a method and apparatus for assembling acomplex product that could produce a variety of different products, thatcould produce a specific number of components when needed, and thatwould require a minimum amount of factory floor space.

SUMMARY OF THE INVENTION

The present invention provides for a method and apparatus for assemblinga complex product in a parallel process system, wherein the methodincludes providing a collection of subcomponents and at least one basecomponent to a loading station for assembling the complex product. Thecollection of subcomponents and the at least one base component areautomatically transported to one of a plurality of similar computerizedassembly cells through the use of a transport system. The collection ofsubcomponents and the at least one base component are automaticallyassembled into the complex product through the use of one of theplurality of similar computerized assembly cells. The complex product isautomatically transported from one of the plurality of similarcomputerized assembly cells to one of the at least one computerized testcells through the use of the transport system. The complex product isautomatically tested in the at least one computerized test cell toensure for the proper assembly functionality of the complex product. Thecomplex product is automatically transported to a delivery stationthrough the use of the transport system.

The steps of providing the collection of subcomponents and the at leastone base component may further comprise the steps of providing a partdelivery system for supplying the at least one base component to thetransport system. A kit delivery system may also be provided forsupplying the subcomponents in a kit container to the transport system.The step of providing a part delivery system may further provide aconveyor for delivering the at least one base component to the transportsystem. The step of providing a kit delivery system for supplying thesubcomponents in the kit container may further provide the steps ofautomatically assembling the subcomponents into the kit containerthrough the use of at least one kit assembly cell. A conveyor may alsobe provided for delivering the kit container to the transport system.The steps of providing a part delivery system may also include the stepsof providing a conveyor for delivering the kit container with saidsubcomponents assembled therein to the transport system.

The steps of transporting the collection of the subcomponents and the atleast one base component may further provide the step of providing anoverhead gantry system for transporting the kit container, the at leastone base component, the complex product to and from the loading station,the plurality of assembly cells, the at least one test cell, and thedelivery station. The step of transferring the collection of thesubcomponents and the at least one base component may, in thealternative, provide a computerized robotic arm for automaticallytransporting the kit container, the at least one base component, thecomplex product to and from the loading station, the plurality ofassembly cells, the at least one test cell, and the delivery station.

The method of the present invention may also include securing the atleast one base component in a rollover fixture in one of the pluralityof computerized assembly cells for rotating the at least one basecomponent in a desired orientation. In addition, the method may includeplacing the kit container within one of the plurality of computerizedassembly cells. The method of the present invention may also includeproviding a computerized tool changer in each of the computerizedassembly cells for automatically providing an appropriate tool forassembling the subcomponents to the at least one base component forforming the complex product. The method also includes providing threeaxes of linear movement between the at least one base component and theappropriate tool. In addition, the method of the present invention mayinclude securing the complex product in the rollover fixture and the atleast one computerized test cell for rotating the complex product in thedesired orientation. The method may include providing a computerizedtest tool changer in each of the at least one test cell forautomatically providing an appropriate test tool for testing the complexproduct. Three axes of linear movement may be provided between thecomplex product and the appropriate test tool.

The apparatus of the present invention for assembling a complex productin a parallel process system may include a loading station for providinga collection of subcomponents and at least one base component requiredfor assembling the complex product. A plurality of computerized assemblycells automatically assemble the subcomponents to the base components toform the complex product. At least one computerized test cellautomatically tests the complex product for the proper assemblyfunctionality of the complex product. A delivery station receives thecomplex product after the complex product is tested. A transport systemtransports the subcomponents, the at least one base component, and thecomplex product to and from the loading station, the plurality ofassembly cells, the at least one test cell, and the delivery station.

The loading station of the apparatus of the present invention mayfurther include a part delivery system for delivering the at least onebase component to the transport system. A kit delivery system delivers akit container having the subcomponents contained therein to thetransport system. The part delivery system of the apparatus of thepresent invention may provide a conveyor for delivering the at least onebase component to the transport system. The kit delivery system of theapparatus of the present invention may further provide a conveyor fordelivering the kit container to the transport system. The kit deliverysystem may also provide an automatic kit assembly cell for receiving andassembling the subcomponents into the kit container. A conveyor deliversthe kit container to the transport system.

The transport system of the apparatus of the present invention furtherprovides a computerized overhead gantry system for automatically pickingand placing the kit container, the at least one base component, thecomplex product to and from the loading station, the computerizedassembly cells, the at least one computerized test cell, and thedelivery station. In the alternative, the transport system may include acomputerized robotic arm for automatically picking and placing the kitcontainer, the at least one base component, and the complex product toand from the loading station, the automatic assembly cell, the at leastone automatic test cell, and the delivery station.

The computerized assembly cells of the apparatus of the presentinvention may include a rollover fixture mounted within each of theassembly cells for securing and rotating the at least one base componentin a desired orientation for assembling the subcomponents thereto. A kitcontainer fixture within each of the computerized assembly cellsreceives the kit container. A computerized tool changer within each ofthe assembly cells automatically provides an appropriate tool forassembling the subcomponents in the kit container to the at least onebase component. A rollover fixture and the computerized tool changer aremoveable with respect to one another in three axes of linear motion.

The at least one computerized test cell of the apparatus of the presentinvention further provides a rollover fixture mounted with each of theat least one automatic test cell for securing and rotating the complexproduct in a desired orientation for testing the complex product. Acomputerized tool changer within the at least one test cellautomatically provides an appropriate test tool for testing the complexproduct. The rollover fixture and the appropriate test tool are moveablewith respect to one another in three axes of linear movement.

The delivery station of the apparatus of the present invention mayfurther provide a first area within the delivery station for receivingthe complex products that are defective. A second area within thedelivery station receives the complex products that are non-defective.

The assembly cells and test cells of the apparatus of the presentinvention may further provide a carriage having the rollover fixture andthe kit container fixture connected thereto. A pair of rails slidinglyreceive the carriage, and the rails extend to and from the assembly celland the test cell, wherein the carriage moves between an unloadedposition, wherein the carriage is outside the assembly cell and testcell, and a loaded position, wherein the carriage is within the assemblycell and the test cell.

BRIEF DESCRIPTION OF THE DRAWINGS

Various other uses of the present invention will become more apparent byreferring to the following detailed descriptions and drawings, andwhich:

FIG. 1 is a description of a prior art method and apparatus forassembling a complex product with the conventional assembly line serialprocess;

FIG. 2 is a description of a prior art method and apparatus forassembling a complex product being converted to an assembly cell of thepresent invention;

FIG. 3 is an overhead isometric drawing of the method and apparatus forassembling a complex product in a parallel process system of the presentinvention;

FIG. 4 is an isometric drawing of an assembly cell of the method andapparatus for assembling a complex product in a parallel process systemof the present invention;

FIG. 5 is an isometric drawing of an assembly cell of the method andapparatus for assembling a complex product in a parallel process systemof the present invention wherein the assembly cell has guard panels andinterlocking doors;

FIG. 6 is a side view of the assembly cell of the method and apparatusfor assembling a complex product in a parallel process system of thepresent invention;

FIG. 7 is an end view of the assembly cell of the method and apparatusfor assembling a complex product in a parallel process system of thepresent invention;

FIG. 8 is an isometric drawing of the test cell of the method andapparatus for assembling a complex product in a parallel process systemof the present invention;

FIG. 9 is a side view of the test cell of the method and apparatus forassembling a complex product in a parallel process system of the presentinvention;

FIG. 10 is an overhead schematic diagram of the kitting cell of themethod and apparatus for assembling a complex product in a parallelprocess system of the present invention;

FIG. 11 is an overhead schematic of the method and apparatus forassembling a complex product in a parallel process of the presentinvention having a kitting cell incorporated therein;

FIG. 12 is an overhead schematic of the method and apparatus forassembling a complex product in a parallel process system of the presentinvention;

FIG. 13 is an overhead schematic of the method and apparatus forassembling a complex product in a parallel process system of the presentinvention utilizing a robotic system as the transport system;

FIG. 14 is an isometric drawing of an alternative embodiment of themethod and apparatus for assembling a complex product in a parallelprocess system of the present invention;

FIG. 15 is an isometric drawing of an alternative embodiment of anassembly cell of the method and apparatus for assembling a complexproduct in a parallel process system of the present invention;

FIG. 16 is a broken isometric drawing of the assembly cell of analternative embodiment of the method and apparatus for assembling acomplex product in a parallel process system of the present invention;

FIG. 17 is an isometric drawing of a carriage and dual linear railsshown in a loaded position of an alternative embodiment of the methodand apparatus for assembling a complex product in a parallel processsystem of the present invention;

FIG. 18 is an isometric drawing of a carriage and dual linear railsshowing the carriage in an unloaded position of an alternativeembodiment of the method and apparatus for assembling a complex productin a parallel process system of the present invention;

FIG. 19 is an isometric drawing of the carriage in an alternativeembodiment of the method and apparatus for assembling a complex productin a parallel process system of the present invention;

FIG. 20 is an isometric drawing showing the tooling arm of analternative embodiment of the method and apparatus for assembling acomplex product in a parallel process system of the present invention;

FIG. 21 is a side view of the tooling arm in an alternative embodimentof the method and apparatus for assembling a complex product in aparallel process system of the present invention;

FIG. 22 is a perspective view showing the automatic tool changers in thealternative embodiment of the method and apparatus for assembling acomplex product in a parallel process system of the present invention;

FIG. 23 is a perspective view showing a low volume system configurationof an alternative embodiment of the method and apparatus for assemblinga complex product in a parallel process system of the present invention;and

FIG. 24 is a perspective view showing a robotic arm used as a toolchanger in an alternative embodiment of the method and apparatus forassembling a complex product in a parallel process system of the presentinvention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring to the drawings, the present invention will now be describedin detail with reference to the disclosed embodiments.

FIGS. 3-14 illustrate a method and apparatus 10 for assembling a complexproduct 12 in a parallel process system of the present invention. Themethod and apparatus 10 for assembling the complex product 12 provides aloading station 13 having a part delivery system 14 and a kit deliverysystem 16 that deliver the necessary components to the apparatus 10 ofthe present invention. A transport system 18, which may include, but isnot limited to, an overhead gantry or a robot system, extends over thelength of the apparatus 10 and independently picks and carries thecomponents from the part delivery system 14 and kit delivery system 16of the loading station 13 to one of a plurality of similar, computerizedassembly cells or workstations 20. In the alternative, the loading andunloading of the components into the assembly cells 20 may be donemanually. Each of the computerized assembly cells 20 is substantiallysimilar and automatically assembles the various components to form thecomplex product 12. Since the assembly cells 20 are similar and performthe same operation, the method and apparatus 10 of the present inventionis described as a parallel process system. Once the assembly of thecomplex product 12 is completed within one of the assembly cells 20, thetransport system 18 transports the complex product 12 from the assemblycell 20 to a computerized test cell or workstation 22. In thealternative, the loading and unloading of the complex product 12 in thetest cell 22 may also be done manually. The complex product 12 isautomatically tested, and the transport system 18 delivers the complexproduct 12 to a delivery station 23. The delivery station 23 has a partreject area or conveyor 24, wherein the complex product 12 is defective,or an automatic part dunnage load system or part return system 26,wherein the complex product 12 is not defective.

The method and apparatus 10 for assembling the complex product 12 in aparallel process system of the present invention is modeled for theassembling and testing of automotive engine cylinder heads. However, thepresent invention is not limited to this application, but rather, thepresent invention may be utilized for assembling and testing othercomplex products (not shown), such as automotive transmission cases,automotive engine piston and rod assemblies, automotive engine pistoninsertions, various non-automotive complex products, applications thatmay involve a certain amount of danger or risk, and applications thatrequire a clean environment. For purposes of the specification, we willrefer to the cylinder head as our complex product 12.

In order to enhance the efficiency of the present invention, the methodand apparatus 10 for assembling the complex product 12 in a parallelprocess system is constructed in a substantially tight spaced, linearformation so as to reduce the amount of factory floor space required forthe present invention. However, it should be noted that the presentinvention is not limited to being linear, but rather, the assembly cells20 may be placed in a substantially parallel relationship, or theapparatus 10 may be configured in a substantial circular or rectangularconfiguration. In the situation where the apparatus 10 is in a linearformation, the transport system 18 may include a computerized overheadgantry conveyor 19 that extends from one end of the apparatus 10 to theother, as seen in FIGS. 3, 11, and 12. The overhead gantry conveyor 19extends upward from the floor of the manufacturing facility through theuse of a plurality of vertical support beams 34. A horizontal supportbeam or guide rail 36 extends from and is connected to the verticalsupport beams 34. The overhead gantry conveyor 19 of the transportsystem 18 has a pair of independent arms 38 that move independentlyvertically but horizontally together along the guide rail 36. The arms38 of the overhead gantry conveyor 19 have tooling 40 formed on the endof the arms 38 to provide the arms 38 with the ability to pick, move,and place various components and parts into particular locations. Theoverhead gantry conveyor 19 of the transport system 18 can be automatedand computerized in that it may respond to communication from theassembly cells 20 and the test cell 22 in determining when and wherecertain components must be moved on the apparatus 10.

In another embodiment, the transport system 18 may include acomputerized robot system 39, as shown in FIG. 13. A robotic arm 41 ismounted on a guide rail 43, which is supported by a plurality ofvertical support beams 45′ extending upward from the floor of themanufacturing facility. The robotic arm 41 moves linearly along theguide rail 43 and may rotate in a number of axes to pick and placevarious components and parts into various locations along the apparatus10. The ability of the robotic arm 41 to move in a number of axes allowsthe workstations 20, 22 of the apparatus 10 to be formed in asubstantially rectangular or oval configuration as shown.

To provide the apparatus 10 with the necessary components to build thecomplex product 12, the loading station 13 provides the part and kitdelivery systems 14, 16 which supply the necessary components to thebeginning of the apparatus 10, as seen in FIGS. 3-13. The part and kitdelivery systems 14, 16 may comprise part and kit delivery conveyors 45that extend from, and therefore carry, the necessary components from onearea of the manufacturing facility to the apparatus 10, or the necessarycomponents may be manually loaded onto the part and kit delivery systems14, 16 at the apparatus 10. However, it should be noted that althoughthe part and kit delivery conveyors 45 are ideally suited for thepresent invention, the part and kit delivery systems 14, 16 of thepresent invention are not limited to part and kit delivery conveyors 45.For instance, automatic guided vehicle systems (not shown) are alsoanticipated for the part and kit delivery system 14, 16.

The part delivery system 14 supplies a machined base component 25 to theapparatus 10, and the kit delivery system 16 supplies a kit container 28having a plurality of sub-components 27 contained therein to theapparatus 10. The kit container 28 contains all of the sub-components 27necessary to properly assemble the base component 25 into the complexproduct 12. For example, in a cylinder head assembly kit, thesub-components 27 in the kit container 28 could include valve springs,valve seals, valve retainers and keys, spark plugs, and lifters, and thebase component 25 could consist of a cylinder head. The kit container 28may be either assembled by a third-party supplier, or the kit containers28 may be completed by an automatic kitting cell or workstation 82integrated into the apparatus 10, as will be described in a furtherembodiment. It should be noted that the present invention is not limitedto the sub-components 27 listed in the kit container 28, but rather, thepresent invention may include any number of sub-components required toassemble the complex products 12. In an alternative embodiment, thesub-component 27 and the base component 25 could be fed directly intothe assembly cells 20 by part chutes.

In order to load the base component 25 and the kit container 28 into theassembly cells 20, the base component 25 and the kit container 28 aretransported to one of the three individual assembly cells 20 by means ofthe transport system 18. Although three assembly cells 20 are shown inthe drawings, it should be noted that the present invention is notlimited to three assembly cells 20, but rather, any number of assemblycells 20 may be utilized depending on the desired output of theapparatus 10. In the situation where the transport system 18 is anoverhead gantry conveyor 19, the arms 38 on the overhead gantry conveyor19 move independently and vertically downward to engage the basecomponent 25 or the kid container 28 from the part and kit deliverysystem 14, 16 through the use of the tooling 40 mounted on the ends ofthe arms 38 of the overhead gantry conveyor 19. The arms 38 then raisethe complex product 12 and the kit container 28 from the part and kitdelivery system 14, 16 and transport the complex product 12 and the kitcontainer 28 laterally together via the overhead gantry conveyor 19 tothe desired assembly cell 20. The arms 38 independently lower the basecomponent 25 and the kit container 28 into the assembly cell 20. Oncethe base component 25 and the kit container 28 are placed within theassembly cell 20, the arms 38 of the overhead gantry conveyor 19 areraised and moved away from the assembly cell 20, thereby allowing theassembly cell 20 to begin the operation of assembling the sub-components27 in the kit container 28 and the base component 25 into the complexproduct 12.

To assemble the base component 25 and the sub-components 27 in the kitcontainer 28 into the complex product 12, each assembly cell 20 issubstantially similar to one another, and thus, the complex product 12is completely assembled by one of the assembly cells 20. The assemblycells 20 of the present invention are advantageous in that they performthe operation of several individual machines and operations. Forexample, in assembling the complex product 12, such as a cylinder head,the conventional assembly line utilizing a serial process involvesoperations including a spark plug install operation 100, a cylinder headrollover operation 102, a cylinder head valve load operation 104, and acylinder head valve key-up operation 106, as seen in FIGS. 1 and 2. Eachof these conventional operations requires individual machines andworkstations to complete each of these operations as previouslymentioned. The assembly cells 20 of the present invention combine all ofthe above-noted operations and equipment needed to assemble the complexproduct 12 into one individual assembly cell 20. The assembly cells 20have a substantially rectangular configuration with guard panels 42 andinterlocking doors 44 to prohibit anyone from entering the assembly cell20 while the assembly cell 20 is in operation, as seen in FIGS. 2-7. Theassembly cell 20 of the present invention is self-standing andindependently supported so that the assembly cell 20 may be freely movedthrough the use of a forklift (not shown) or overhead crane (not shown).Once the assembly cell 20 is in its desired location, the assembly cell20 may be anchored to the floor of a manufacturing facility through theuse of conventional anchoring fasteners 46. The maneuverability of theassembly cell 20 provides additional flexibility in the presentinvention in that the apparatus 10 of the present invention may be movedor reconfigured with a minimum amount of effort compared to conventionalassembly lines.

As previously mentioned, the base component 25 is placed into theassembly cell 20 by the transport system 18, and the base component 25is pneumatically clamped by a rollover fixture 48. The rollover fixture48 holds the base component 25 and allows the base component 25 torotate 360° so as to position the base component 25 in any desiredorientation. A servo driven “Alpha axis” 50 is connected to the rolloverfixture 48 and provides for the powered rotation of the rollover fixture48. When the kit container 28 is placed in the assembly cell 20, thetransport system 18 places the kit container 28 on a table 52 secured toa platform 54 within the assembly cell 20. The table 52 may have acounter-sunk edge or locators to locate and hold the kit container 28 ina proper position.

In order for all of the sub-components 27 in the kit container 28 to beassembled to the base component 25, the assembly cell 20 provides motionin three dimensions of linear movement as well as rotational movement.As previously noted, the rollover fixture 48 for holding the basecomponent 25 provides for rotational movement of the base component 25.The rollover fixture 48 is mounted on the same platform 54 that supportsthe table 52 for holding the kit container 28. The platform 54 ismounted on a first servo-driven rack and pinion gear 56 that providesfor linear “X” axis movement of the base component 25 and the kitcontainer 28. The “X” axis servo-driven rack and pinion gear 56 ismounted on the base of the assembly cell 20. A second servo-driven rackand pinion gear 58 is also mounted along one side of the assembly cell20 and provides a “Y” axis movement lengthwise across the assembly cell20. Two servo-driven “Z1” and “Z2” axis vertical ball screw slides 60are connected to the “Y” axis. The “Z1” and “Z2” vertical ball screwslides 60 provide movement up and down or substantially perpendicular tothe “Y” axis servo-driven rack and pinion gear 58. The ends of theservo-driven “Z1” and “Z2” axis vertical ball screw slides 60 have aquick change tooling head 62 containing a number of tools 64 to performspecific assembling operations. The quick change tooling head 62 allowsfor other tooling heads 66 to be utilized on the servo-driven “Z1” and“Z2” axis vertical ball screw slide 60.

To utilize the other tooling heads 66, an automatic eight-position toolchanger 68 is mounted to the base of the assembly cell 20. Each of theeight positions of the tool changer 68 provide for a different toolinghead 66 to be housed during the assembly process. Each quick changetooling head 66 provides separated tooling for completing a differentassembly operation of the sub-components 27 in the kit container 28 andthe base component 25 to form the complex product 12. The “Y” axis rackand pinion has the ability to transfer over the desired tooling head 62,66 in the appropriate position for the “Z1” and “Z2” axis ball screwslide 60 to exchange tooling heads 62, 66.

In order to have the assembly cell 20 perform the necessary assemblyoperations to form the complex product 12, a programmable controller 76is mounted on a side of the assembly cell 20. The assembly cellprogrammable controller 76 provides electronic communication between theservo drives 50, 56, 58, 60 and the tool changer 68 to ensure that theappropriate tooling head 62, 66 and tools 64 are utilized and that theappropriate moves are made with the tools 64 to ensure for properassembly of the sub-components 27 and base component 25 into the complexproduct 12.

To ensure that the complex product 12 has been properly assembled, thetest cell 22 is located further along the transport system 18 adjacentto the last assembly cell 20. Although a single test cell 22 is shown inFIGS. 3, 11, and 12, it should be noted that the present invention isnot limited to a single test cell 22, but rather, any number of testcells 22 (for example, two test cells 22 in FIG. 13) may be utilizeddepending on the desired throughput of the apparatus 10. In analternative embodiment, the test cell 22 may even be integrated into theassembly cell 20. The test cell 22 is similarly constructed to theassembly cells 20 in that the test cell 22 has a substantiallyrectangular configuration with guard panels 42 and interlocking doors 44surrounding the test cell 22 to prohibit the entry of any persons whilethe test cell 22 is in operation, as seen in FIGS. 8 and 9. The testcell 22 has a similar rollover fixture 48 to the one provided in theassembly cells 20 for receiving the assembled complex product 12 withinthe test cell 22. Thus, the rollover fixture 48 pneumatically clamps thecomplex product 12, and a servo driven “Alpha axis” 50 provides forrotation of the assembled complex product 12 360° in order to access allareas of the assembled complex product 12. The rollover fixture 48 issimilarly mounted on a servo-driven “X” axis rack and pinion gear 56 asthe assembly cells 20 to provide movement of the assembled complexproduct 12.

To automatically test the assembled complex product 12, a secondservo-driven “Y” axis rack and pinion gear 58, as similarly utilized inthe assembly cells 20, is mounted along one side of the test cell 22. Aservo-driven “Z” axis single vertical ball screw slide 60, as similarlyutilized in the assembly cells 20, is mounted to the servo-driven “Y”axis rack and pinion gear 56, thereby providing movement along the Y andZ axis to a quick change test tooling head 62 mounted on the end of the“Z” axis servo-driven ball screw slide 60. The quick change test toolinghead 62 allows for the test tools 64 to be interchanged with variousother test tooling heads 66. The test cell 22 also has an automaticeight-position tool changer 68, as similarly utilized in the assemblycells 20. Each of the positions of the tool changer 68 holds a test toolheads 66. This allows for the interchanging of test tools 64 on the “Z”axis servo-driven ball screw slide 60.

Communication between the servo drives 50, 56, 58, 60 and the toolchanger 68 is provided through programmable controller 80 mounted on theside of the test cell 22. The programmable controller 80 coordinates themovement and operation of the servo drives 50, 56, 58 and the toolchanger 68 to ensure for the appropriate movement and operation of thetest tools 64 for testing the assembly functionality of the assembledcomplex product 12. The programmable controller 80 will also determinewhether the complex product 12 is defective or whether the complexproduct 12 is dimensionally and functionally acceptable. The test cellprogrammable controller 80 is also in electronic communication with theassembly cell programmable controllers 76 to ensure all programmableequipment is in concert with one another.

Once the assembled complex product 12 has been tested in the test cell22, the transport system 18 removes the assembled complex product 12from the test cell 22 to the delivery station 23. If the test cell 22determines that the assembled complex product 12 is defective, i.e., acomponent has not been properly assembled in the complex product 12, aparticular portion of the complex product 12 is not in tolerance, aportion of the complex product 12 is not functioning properly, etc.,then the transport system 18 carries the defective complex products 12to the part reject area or conveyor 24 of the delivery station 23, asseen in FIGS. 3 and 10-14. The part reject area or conveyor 24 of thedelivery station 23 is positioned further along the transport system 18and adjacent to the test cell 22. Once the defective complex product 12is placed on the part reject area or conveyor 24 of the delivery station23, the defective complex product 12 may be further analyzed andreworked, or the defective complex product 12 may be carried to astorage area (not shown), wherein the defective complex product 12 maybe collected by a laborer.

A kit container return conveyor 30 may also extend adjacent to andsubstantially parallel to the part reject area or conveyor 24 of thedelivery station 23. The transport system 18 collects the empty kitcontainers 28 from the assembly cells 20 once the sub-components 27 havebeen removed from the kit container 28 and assembled to the basecomponent 25 to form the complex product 12. The transport system 18transfers the empty kit container 28 from the assembly cells 20 to thekit container return conveyor 30, where the kit containers 28 may becollected, refilled, and returned to the beginning of the apparatus 10.

If the assembled complex product 12 passes inspection in the test cell22, then the transport system 18 removes the assembled complex product12 from the test cell 22 and transfers the assembled complex product 12to the automatic part dunnage or part return system 26 of the deliverystation 23. From there, the completed complex product 12 is transferredto another location, where the completed complex product 12 may beinstalled as a sub-assembly in another product.

In another embodiment, the kit container 28 may be automatically filledwith the sub-components 27 in the kitting cell 82, as opposed todelivering the kit container 28 pre-filled with the sub-components 27 tothe kit delivery system 16, as seen in FIGS. 10 and 11. The kitting cell82 is positioned under the starting end of the transport system 18, andthe kitting cell 82 has a rectangular configuration that is enclosed byguarding panels 42 and interlocking doors 44, similar to the assemblycells 20 and the test cell 22 as seen in FIGS. 4-5 and 8-9. Aservo-driven “Y1” and “Y2” dual independent rack and pinion gantry 84 ismounted along one side of the kitting cell 82. A servo-driven “X” axisrack and pinion slide 86 supports the kit container 28 and providesmovement of the kit container 28 along the X axis. A servo-driven “Y3”axis comb escapement 88 receives various sub-components 27. For example,in a cylinder assembly line, the valve seal 90, the valve springs 92,and the valve retainer and key 94 may be received from separatepart-feeding systems 96. By moving the servo-driven “Y2” axis rack andpinion gantry 84 slide over the servo-driven “Y3” axis comb escapement88, the valve sub-components 90, 92, 94 may be picked and placed intothe kit container 28. At the opposite side of the kitting cell 82, apair of valve sub-component conveyors 98 delivers sub-components 27, forexample, in a cylinder head assembly line, such sub-components mayconsist of valves and spark plugs. The servo-driven “Y1” rack and piniongantry slide moves over the valve sub-component conveyors 98, whereinthe sub-components 27 can be loaded into the kit container 28. Once thekit container 28 is loaded with the sub-components 27, the transportsystem 18 picks and lifts the kit container 28 from the kitting cell 82and transfers the kit container 28 to one of the assembly cells 20.

In operation, the kit containers 28 are supplied to the apparatus 10 bythe kit delivery system 16, which may utilize the kit delivery conveyor45 to deliver the kit containers 28 in a filled state, or the kitdelivery system 16 may utilize the kitting cell 82 to fill the kitcontainers 28 with the appropriate sub-components, as previouslydescribed and shown in FIGS. 3-13. The base component 25 is supplied tothe apparatus 10 by the part delivery system 14, which may utilize thepart and kit delivery conveyor 45 for loading the complex product 12.The transport system 18 picks up and places the base component 25 intothe rollover fixture 48 in one of the assembly cells 20. In addition,the transport system 18 picks up a kit container 28 and places the kitcontainer 28 on the table 52 in the same assembly cell 20. The assemblycell 20 assembles each sub-component 27 in the kit container 28 to thebase component 25 by using a particular tooling head 62, 66. The toolingheads 62, 66 will be exchanged so that each of the respectivesub-components 27 will be assembled to the base component 25 with theappropriate tools 64. Once the complex product 12 is completelyassembled, the transport system 18 removes the assembled complex product12 and transfers the complex product 12 to the test cell 22. Inaddition, the empty kit container 28 is removed from the assembly cell20 by the transport system 18 and transferred to the kit containerreturn conveyor 30. Once the assembled complex product 12 is placed inthe rollover fixture 48 of the test cell 22, the test cell 22automatically performs the appropriate testing to ensure that thecomplex product 12 is not defective. If the test cell 22 determines thatthe assembled complex product 12 is defective, then the transport system18 removes the defective complex product 12 and places it on the partreject area or conveyor 24 of the delivery station 23, wherein thedefective complex product 12 may be reworked or transferred to anotherarea. If the test cell 22 determines that the assembled complex product12 is not defective, then the transport system 18 removes the assembledcomplex product 12 from the test cell 22 and transfers the assembledcomplex product 12 into the automatic part dunnage load system or partreturn system 26 of the delivery station 23. The complex products 12 maythen be transported to a desired area.

In an alternative embodiment to the method and apparatus 10 forassembling the complex product 12 in a parallel process system of thepresent invention, the loading station 13 has a part delivery system 14and a kit delivery system 16, as previously described. In addition, thedelivery station 23, as previously described, may also be provided.However, the assembly cells 20 and the test cell 22 may take on severaldifferent features. As seen in FIGS. 14-16, assembly cells 200 and atest cell 201 have a similar overall configuration to thepreviously-described assembly cells 20 and test cell 22; however, duallinear rails 202, as seen in FIGS. 14-19, allow the kit containers 28and base components 25 to be loaded outside the assembly cell 200 andtest cell 201 by having the dual linear rails 202 extend from theoutside to the inside of the assembly cell 200 and test cell 201. Thisallows the individual assembly cells 200 and test cell 201 to bestaggered, as shown in FIG. 14. With this type of configuration, thetransport system 18, as previously described, loads and unloads the kitcontainers 28, the base component 25, and the complex product 12 fromoutside the assembly cells 200 and the test cell 201. By staggering theassembly cells 200 and test cell 201, the ends of the linear rails 202are linearly aligned directly under the transport system 18. Thisparticular configuration allows for a high volume of output of thecomplex product 12.

In order to move the kit containers 28, base component 25, and complexproduct 12 to and from the assembly cells 200 and test cells 201, acarriage 204 is slidably attached to the dual linear rails 202 and movesbetween an unloaded position, wherein the carriage 204 is outside theassembly cell 200 or test cell 201, and a loaded position, wherein thecarriage 204 is inside the assembly cell 200 or test cell 201. Thecarriage 204 is driven between the unloaded position and the loadedposition through the use of a belt drive 206. The carriage 204 includesa rotational fixture 208 for engaging and rotatably positioning the basecomponent 25 in the assembly cell 200 and the complex product 12 in thetest cell 201 in a predetermined orientation. In addition, the carriage204 provides a pair of fixtures 210 adjacent each side of the rotationalfixture 208 for engaging a pair of kit containers 28. The kit containers28 have a pair of clips 211 which extend from the ends of the kitcontainer 28 to complementarily engage the fixture 210 and secure thekit container 28 to the carriage 204. Once the kit containers 28 andbase component 25 are loaded onto the carriage 204, the carriage 204 maybe moved to the loaded position within the assembly cell 200. Similarly,once the complex product 12 is loaded on the carriage 204, the carriage204 may be moved to the loaded position in the test cell 201. A servodrive 212 mounted at the end of the dual linear rails 202 within theassembly cell 200 and test cell 201 may engage and rotate a shaft 213 onthe rotational fixture 208 in the desired position when the carriage 204is in the loaded position. The transport system 18, as previouslydescribed, loads the kit containers 28 and the base component 25 intothe carriage 204 of the assembly cell 200 when the carriage 204 is inthe unloaded position. Similarly, the transport system 18 may load thecomplex product 12 into the carriage 204 of the test cell 201 when thecarriage 204 is in the unloaded position.

When the carriage 204 is in the loaded position within the assembly cell200 and test cell 201, a pair of substantially parallel rails 214extends substantially perpendicular from both sides of the dual linearrails 202, as seen in FIGS. 16 and 22. Each set of substantiallyparallel rails 214 has a plurality of assembly tools 216 in the assemblycell 200 and test tools 216 in the test cell 201 that are nested betweenthe substantially parallel rails 214. The tools 216 have a tool adapterplate 217 which has apertures 219 extending there through for engagingpins 222 on the substantially parallel rails 214 for securing andlocating the tools 216. Each tool 216 is different in order to performdifferent assembly and test functions on the complex product 12. Eachtool 216 has a quick change adapter 218 which may be engaged anddisengages by a tool arm 220. Through the use of the quick changeadapter 218, the tool arm 220 can quickly engage and disengage therespective tool 216.

As seen in FIGS. 20 and 21, the tool arm 220 may be driven along aZ-axis through the use of a ball screw and servo 224, thereby allowingfor the lifting and lowering of the assembly and test tools 216 from thesubstantially parallel rails 214. The tool arm 220 may also be drivenlength-wise along the assembly cell 200 and test cell 201 by a rack andpinion Y-axis gantry 221 and servo, thereby allowing the assembly tool216 to be moved to and from the kit containers 28 and the base component25 in the assembly cell 200, or by allowing the test tool 216 to be moveto and from the complex product 12. By having a pair of tooling arms 220and kit containers 28 on each side of the dual linear rails 202, thesub-components 27 and the base component 25 can be assembled into thecomplex product 12 in a timelier manner. Similarly, the pair of toolingarms 220 in the test cell 201 can expedite the testing of the complexproduct 12. In the alternative embodiment, the tool arm 220 may compriseof a robotic arm 230, as seen in FIG. 24, which is driven along a rail232 and provides multiple degrees of movement.

The test cell 201 of this embodiment of the present invention is similarto the assembly cell 200 except that the complex product 12 is loadedinto the carriage 204, as opposed to the kit container 28 and basecomponent 25. In addition, testing tools 216 are utilized in the testcell 201, as opposed to assembly tools 216 in the assembly cells 200.Structurally, the assembly cells 200 and test cell 201 remain the same.

It should be noted that in another embodiment, a low volume systemconfiguration of the present invention may be employed by having anassembly cell 200 and a test cell 201 opposite one another with theloading station conveyor 225, 226 and the delivery station conveyor 227extending between the assembly cell 200 and the test cell 201, as seenin FIG. 23. Thus, the kit container 28 and the base components 25 may bemanually loaded onto the carriage 204 of the assembly cell 200, or thekit container 28 and the base components 25 may be automatically loadedthrough one of the previously-described transport systems 18. Loadingthe complex products 12 into the testing cell 201 may also be donemanually or automatically.

While the invention has been described in connection with what ispresent considered to be the most practical and preferred embodiment, itis to be understood that the invention is not to be limited to thedisclosed embodiments, but to the contrary, it is intended to covervarious modifications or equivalent arrangements included within thespirit and scope of the appended claims. The scope is to be accorded thebroadest interpretation so as to encompass all such modifications andequivalent structures as is permitted under the law.

1. A method for assembling a complex product in a parallel processsystem, the steps comprising: providing a collection of sub-componentsand at least one base component to a loading station for assembling saidcomplex product; automatically transporting said collection ofsub-components and said at least one base component to one of at leastone similar computerized assembly cells through the use of a transportsystem; automatically assembling said collection of sub-components andsaid base component into said complex product through the use of said atleast one computerized assembly cell; automatically transporting saidcomplex product to a delivery station through the use of said transportsystem; automatically transporting said complex product from said atleast one assembly cell to one of at least one similar computerized testcells through the use of said transport system; and automaticallytesting said complex product in said at least one computerized test cellto ensure for the proper assembly functionality of said complex product.2. The method as stated in claim 1, wherein said step of providing acollection of sub-components and at least one base component furthercomprise the steps of: manually loading said sub-components and said atleast one base component into said transport system.
 3. The method asstated in claim 1, wherein said step of providing a collection ofsub-components and at least one base component further comprise thesteps of: providing a part delivery system for supplying said at leastone base component to said transport system; and providing a kitdelivery system for supplying said sub-components in a kit container tosaid transport system.
 4. The method as stated in claim 3, wherein saidstep of providing a part delivery system further comprises the steps of:providing a conveyor for delivering said at least one base component tosaid transport system.
 5. The method as stated in claim 4, wherein saidstep of providing a kit delivery system for supplying saidsub-components in a kit container further comprises the steps of:automatically assembling said sub-components into said kit containerthrough the use of at least one kit assembly cell; and providing aconveyor for delivering said kit container to said transport system. 6.The method as stated in claim 3, wherein said step of providing a partdelivery system further comprises the steps of: providing a conveyor fordelivering said kit container with said sub-components assembled thereinto said transport system.
 7. The method as stated in claim 3, whereinsaid step of transporting said collection of said sub-components andsaid at least one base component further comprise the steps of:providing an overhead gantry system for transporting said kit container,said at least one base component, and said complex product to and fromsaid loading station, said plurality of assembly cells, said at leastone test cell, and said delivery station.
 8. The method as stated inclaim 3, wherein said step of transferring said collection of saidsub-components and said at least one base component further comprisesthe steps of: providing a computerized robotic arm for automaticallytransporting said kit container, said at least one base component, andsaid complex product to and from said loading station, said plurality ofassembly cells, said at least one test cell, and said delivery station.9. The method stated in claim 3, further comprising the steps of:securing said at least one base component in a rollover fixture in oneof said plurality of computerized assembly cells for rotating said atleast one base component in a desired orientation; and placing said kitcontainer within one of said plurality of computerized assembly cells.10. The method stated in claim 1, further comprising the steps of:providing a computerized tool changer in each of said computerizedassembly cells for automatically providing an appropriate tool forassembling said sub-components to said at least one base component forforming said complex product; and providing three axes of linearmovement between said at least one base component and said appropriatetool.
 11. The method stated in claim 1, further comprising the steps of:securing said complex product in a rollover fixture in said at least onecomputerized test cell for rotating said complex product an a desiredorientation; providing a computerized test tool changer in each of saidat least one test cell for automatically providing an appropriate testtool for testing said complex product; and providing three axes oflinear movement between said complex product and said appropriate testtool.
 12. An apparatus for assembling a complex product in a parallelprocess system comprising: a loading station for providing a collectionof sub-components and at least one base component required forassembling said complex product; a plurality of computerized assemblycells for automatically assembling said sub-components to said basecomponents to form said complex product; a delivery station forreceiving said complex product after said complex product is assembled;a transport system for transporting said sub-components, said at leastone base component, and said complex products to and from said loadingstation, said plurality of assembly cells, and said delivery station;and at least one computerized test cell for automatically testing saidcomplex product to test for the proper assembly functionality of saidcomplex product.
 13. The apparatus stated in claim 12, wherein saidloading station further comprise: manually loading said sub-componentsand said base component into said transport systems.
 14. The apparatusas stated in claim 12, wherein said loading station further comprises: apart delivery system for delivering said at least base component to saidtransport system; and a kit delivery system for delivering a kitcontainer having said sub-components contained therein to said transportsystem.
 15. The apparatus as stated in claim 12, wherein said partdelivery system further comprises: a conveyor for delivering said atleast one base component to said transport system.
 16. The apparatus asstated in claim 12, wherein said kit delivery system further comprises:a conveyor for delivering said kit container to said transport system.17. The apparatus as stated in claim 12, wherein said kit deliverysystem further comprises: an automatic kit assembly cell for receivingand assembling said sub-components into said kit container; and aconveyor for delivering said kit container to said transport system. 18.The apparatus as stated in claim 12, wherein said transport systemfurther comprises: a computerized overhead gantry system forautomatically picking and placing said kit container, said at least onebase component, and said complex product to and from said loadingstation, said computerized assembly cells, said at least onecomputerized test cell, and said delivery station.
 19. The apparatus asstated in claim 18, further comprising: a carriage having said rolloverfixture and kit container fixture connected thereto; and a pair of railsfor slidably receiving said carriage, and said rails extending to andfrom said assembly cell wherein said carriage moves between an unloadedposition, wherein said carriage is outside said assembly cell, and aloaded position, wherein said carriage is within said assembly cell. 20.The apparatus as stated in claim 12, wherein said transport systemfurther comprises: a computerized robotic arm for automatically pickingand placing said kit container, said at least one base component, andsaid complex product to and from said loading station, said automaticassembly cell, said at least once automatic test cell, and said deliverystation.
 21. The apparatus as stated in claim 12, wherein each of saidcomputerized assembly cells further comprise: a roll-over fixturemounted within each of said assembly cells for securing and rotatingsaid at least one base component in a desired orientation for assemblingsaid sub-components thereto; a kit container fixture within each of saidcomputerized assembly cells for receiving said kit container; acomputerized tool changer within each of said assembly cells forautomatically providing an appropriate tool for assembling saidsub-components in said kit container to said at least one basecomponent; and said roll-over fixture and said computerized tool changermoveable with respect to one another in three axes of linear motion. 22.The apparatus as stated in claim 12, wherein each of said at least onecomputerized test cell further comprises: a roll-over fixture mountedwithin each of said at least one automatic test cell for securing androtating said complex product in a desired orientation for testing saidcomplex product; a computerized tool changer within said at least onetest cell for automatically providing an appropriate test tool fortesting said complex product; and said roll-over fixture and saidappropriate test tool moveable with respect to one another in three axesof linear movement.
 23. The apparatus as stated in claim 12, whereinsaid delivery station further comprises: a first area within saiddelivery station for receiving said complex products that are defective;and a second area within said delivery station for receiving saidcomplex products that are non-defective.